Inspection and Repair
GENERAL1. Smear a light coat of petroleum jelly into the pump recess.
2. Renew O-ring and press pump unit firmly into recess.
NOTE: Ensure "TOP" marking on pump is to top of casing.
3. Tap pump lightly at edges until fully home.
NOTE: Ensure good thread engagement before tightening.
4. Install new mainshaft support bearing.
5. Install new mainshaft rear oil seal using tool LRT-37-014.
6. ON new Layshaft support bearing.
7. Install new oil pick-up ring (Align tag with center of drain slot).
8. Examine gate plate and renew H worn or damaged.
9. Rem reverse light switch with new copper washer.
- Tighten to 24 Nm.
10. Install reverse inhibition cam and spring.
11. Apply Hylogrip 640 and install shaft.
12. Install oil pipe, bend uppermost.
GEAR CHANGE HOUSING - TYPE A GEARBOX, OVERHAUL
Dismantle
1. Using a suitable piece of tubing, release both ends of bias spring from W1 pins.
2. Slacken locknuts and remove bias spring adjusting screws.
3. Drift out roll pin, remove bias spring.
4. Remove extension from lower gear lever.
5. Remove bolt and special washer securing lower gear lever.
6. Carefully withdraw lower gear lever from housing ensuring that spring loaded nylon pad is retained during removal.
WARNING: Personal injury may result if pad is not retained.
7. Release nylon pad, recover spring.
8. Clean all components.
Inspection
1. Check lower gear lever ball pin for wear, replace H necessary.
CAUTION: If lower gear lever is to be replaced then bad pin seating, located in remote housing should also be replaced.
2. Check nylon pad and spring for wear and damage, replace H necessary.
3. Check bias spring roll pin for damage, replace if necessary.
Reassemble
1. Smear ball pin with multi - purpose grease and m spring and nylon pad.
2. Depress nylon pad against spring pressure, position lower gear lever in housing.
CAUTION: Ensure nylon pad is facing away from bias spring location.
3. Install lower gear lever retaining bolt and special washer, tighten bolt to 16 Nm.
4. Install extension to lower gear lever.
5. Position roll pin to housing, install roll pin.
6. At bias spring adjusting screws and locknuts.
7. .Using a suitable piece of tubing locate both ends of bias spring over ball pins.
NOTE: Do not adjust bias spring at this stage.
REMOTE HOUSING - TYPE A GEARBOX, OVERHAUL
Dismantle
1. Remove setscrew securing trunnion to selector shah, remove trunnion.
2. Remove and discard circlip securing ball pin seating to trunion, remove seating.
3. Slacken locknut, remove 6th gear stop screw.
CAUTION: Retain shim(s).
4. Remove blanking plug from end of remote housing.
5. Remove setscrew securing quadrant to selector shaft, remove quadrant.
6. Remove selector shaft from remote housing, remove and discard O-ring.
7. Remove and discard circlip retaining rollers and pin to quadrant.
8. Remove pin, recover rollers.
Inspection
1. Check selector shaft and bore in remote housing for wear.
2. Check quadrant rollers and pin for wear.
3. Check ball pin seating for wear.
4. Replace worn components as necessary.
Reassemble
1. Lubricate selector shaft and new O-ring with gearbox oil.
2. Install O-ring to selector shaft.
3. Install shaft to remote housing.
4. Position rollers to quadrant, install pin and secure with new circlip.
CAUTION: Ensure that head of pin is on opposite side of quadrant to selector shaft boss.
5. At quadrant to selector shaft.
6. Apply Loctite 270 to threads of setscrew, m and tighten setscrew.
7. Apply Loctite 270 to threads of blanking plug, install and tighten plug.
8. Smear ball pin seating with multi - purpose -grease.
9. Position ball pin seating in trunnion, secure with a new circlip.
10. Position trunnion on selector shaft.
11. Apply Locate 270 to threads of setscrew, install and tighten setscrew.
12. Install 5th gear stop screw, m but do not tighten locknut
NOTE: 5th gear stop screw adjustments carried out during gearbox reassembly.
GEAR CHANGE HOUSING - TYPE B GEARBOX, OVERHAUL
Dismantle
1. Remove bolts retaining bias springs.
WARNING: To avoid personal injury, restrain each spring in turn with a pair of grips while the bolts are being removed.
2. Remove the two springs.
3. Remove remaining bolts to release lower lever assembly.
4. Remove and discard Railko bush.
5. Remove and discard oil seal.
Inspection
1. Check ball cross pin slots in gear change housing for wear.
2. Check ball and pins for wear.
3. Check bias springs for distortion.
4. Replace worn components as necessary.
Reassemble
1. Apply multi-purpose grease to ball and cross pins.
2. Apply multi-purpose grease to new Railko bush and install to gear change housing.
CAUTION: Ensure that the slots in each bush are aligned with slots in housing.
3. Lubricate a new oil seal with gearbox oil.
4. EN oil seal using a sunable mandrel.
5. Position gear lever to gear change housing ensuring ball cross pins are located in slots in housing and Railko bush.
6. Position bias spring adjustment plate to gear change housing,
7. Apply Loctite 270 to threads of 2 short bias adjustment plate bolts.
8. Install bolts to secure front of bias adjustment plate and tighten to 25 Nm.
9. Position bias spring to pillar ensuring longest end of spring is against gear lever.
10. Apply Loctite 270 to threads of 2 long bias bias adjustment plate bolts.
11. Restrain bias spring using a suitable pair of grips, ensure short end of bias spring is positioned on outside edge of bolt hole.
WARNING: Personal injury may result if bias spring is not retained
12. In bolt and washer ensuring end of bias spring is retained beneath washer; tighten bolt to 25 Nm.
13. Repeat procedure for remaining bias spring.
REMOTE GEAR CHANGE - TYPE C GEARBOX, OVERHAUL
Dismantle
1. Remove 2 bolts and 2 countersunk screws securing bias spring bridge plates.
2. Remove bridge plates, bridge plate liners and bias spring.
3. Remove 4 bolts and washers securing bottom cover plate, remove plate.
4. Remove bolt securing gear lever cap, remove cap.
5. Remove gear lever, recover anti-rattle spring and plunger.
6. Remove pinch bolt securing selector rod yoke, remove yoke.
7. Withdraw selector rod from remote housing.
8. Clean components.
REMOTE GEAR CHANGE - TYPE D GEARBOX, OVERHAUL
NOTE:
^ The remote gear change installed to Type D gearboxes is not repairable item.
^ It must be renewed if it is found to be excessively worn.
Inspection
1. Check selector rod bushes in remote housing for wear.
NOTE: Bushes may be pressed in and out of remote housing using a hand press and suitable mandrel.
2. Check selector rod for wear, replace if necessary.
3. Check ante - rattle spring for distortion and plunger for wear; replace if necessary.
4. Check gear lever ball pin, cross pins and bush selector rod yoke balls for wear, and replace if necessary.
- If yoke balls are worn, remove and discard circlip, press ball and seating out of yoke.
5. Lubricate replacement ball and seating with multi - purpose grease and press into yoke; secure using new circlip.
6. Check bias spring for distortion, replace if necessary.
7. Check condition of mounting rubbers, replace as a set if necessary.
Reassemble
1. Lubricate selector rod and bushes with multi -purpose grease, insert rod in remote housing.
2. Lubricate gear lever ball pin and selector rod yoke balls with multi - purpose grease.
3. Install yoke to selector rod, install and Lighten pinch bolt.
4. Assemble ante - rattle spring and plunger to gear lever.
5. Install gear lever ensuring ball pin is located in yoke and anti - rattle spring and plunger are not displaced.
6. Install gear lever cap, install and tighten bolt
NOTE: Do not bottom cover plate at this stage.
7. Slacken bias spring adjustment bolt locknuts.
8. Install bias spring, bridge plate liners and bridge plates.
9. Install and tighten bolts and countersunk screws.
NOTE: Final adjustment of bias spring is earned out after remote gear change is Fred to gearbox.
TRANSFER BOX SELECTOR HOUSING - TYPE A GEARBOX, OVERHAUL
Dismantle
1. Slide gaiter off gear lever.
2. Remove 4 bolts securing gaiter support plate and gate plate.
3. Remove gaiter support plate and gate plate, discard gaskets.
4. Remove and discard spring clip retaining selector fork clevis pin.
5. Remove clevis pin from selector fork, remove and discard 2 bushes.
6. Remove and discard circlip retaining nylon ball seating.
7. Remove gear lever, recover nylon seating and ball.
8. Remove 2 countersunk head screws securing end cover to housing.
9. Remove end cover, remove and discard 2 O-rings.
10. Withdraw cross shaft.
11. Remove selector fork, remove and discard 2 O-rings.
12. Clean all components.
Inspection
1. Check gaiter for splits and damage.
2. Check nylon seating and ball for wear, replace if necessary.
CAUTION: Seating and ball should be renewed as an assembly.
3. Check selector fork and clevis pin for wear.
4. Check cross shaft and end cover for wear.
5. Replace components as necessary.
Reassemble
1. Smear new O-rings with gearbox oil and install to selector fork, position fork in housing.
2. Smear cross shaft with muff - purpose grease and locate longest end of shaft in selector fork.
3. Smear new O-rings with gearbox oil and install to end cover.
4. Position end cover on cross shaft, install and tighten countersunk screws.
5. Assemble ball and nylon seating to gear lever ensuring that groove in seating is towards cross shaft.
6. Smear ball and nylon seating with multi -purpose grease and locate in cross shaft; retain with a new circlip.
7. Position new bushes to gear lever, locate in selector fork and install clevis pin.
8. Install new spring clip to retain clevis pin.
9. Position gate plate and gaiter support plate to housing, use new gaskets.
10. Install retaining bolts and tighten to 15 Nm.
11. Install gaiter.
SYNCHROMESH ASSEMBLIES - OVERHAUL
Dismantle and Inspection
1. Remove spring clips from both sides of assembly.
2. Remove slippers and separate the hub from the sleeve.
3. Examine all parts for damage and wear including spring clips for tension.
4. Check no excessive radial movement exist between inner members and mainshaft splines.
5. Examine inner and outer splines for wear.
6. Examine the dog teeth on all gears for wear and damage.
NOTE:
^ Example "A" shows a tooth in good condition.
^ Example "B" shows the rounded comers of a worn tooth.
7. Replace unit if excessively worn.
Reassembly
8. Install inner hub to sleeve.
NOTE:
^ Hubs end sleeves have a master spline combination end can only be assembled one way.
^ The sleeves are further identified ninth a series of half moon notches which clearly identify which side of the assembly faces which gear.
^ Ensure the slot in the hub aligns with the center notch on the sleeve
Assembly: 1st/2nd
Hub Marking: -
Sleeve Marking: 1 Notch
Against Gear: 1st
Hub Marking: 2nd Gear Side
Sleeve Marking: -
Against Gear: 2nd
Assembly: 3rd/4th
Hub Marking: -
Sleeve Marking: 3 Notches
Against Gear: 3rd
Hub Marking: -
Sleeve Marking: -
Against Gear: 3rd
Assembly: 5th/Rev
Hub Marking: -
Sleeve Marking: 5 Notches
Against Gear: 5th
9. Install slippers and secure with a spring each side of the synchromesh assembly ensuring the step on each spring locates on a deferent slipper.
NOTE: 5th and reverse synchromesh hubs have different springs noted by their yellow color.
CHECKING BAULK RING CLEARANCES
Check clearance of all baulk rings and gears by pressing the baulk rings against the gear and measuring the gap. The minimum clearance should be 0.5mm (0.0200 inch).
INPUT SHAFT - OVERHAUL
1. Examine the gear and dog teeth for wear and damage.
2. Using tool LRT-99-004 and LRT-37-004 remove pilot bearing race.
NOTE: Ensure that Me bearing is supported by me lip inside LRT-37-001.
3. Using LRT-37-001 and LRT-99-002 remove taper roller bearing.
4. Support the shaft under LRT-99-002 and press in a new pilot bearing race.
5. Using LRT-9-002, Collets LRT-37-001 and adapter LRT-37-002 install a new taper bearing.
MAINSHAFT- INSPECTION
1. Examine bearing journals for wear and scores.
2. Examine splines for wear and damage.
3. Use an air line to check that the main oil feed from pump and feed to spigot bearing are clear.
4. Check oil feed holes to roller bearing are clear.
LAYSHAFT - OVERHAUL
1. Using extractor tool LRT-99-002 and collets LRT-37-022 withdraw layshaft bearings.
2. Examine layshaft for wear and damage.
NOTE:
^ Layshaft and layshaft 5th gear installed to later gearboxes are machined to enable installment of a split washer to prevent gear movement on shad
^ The modified layshaft, gear end spy washer may be installed to early gearboxes as an assembly.
3. Using press LRT-99-002, and support bars install new taper roller bearings.
MAINSHAFT- REASSEMBLY
1. Clamp mainshaft in protected vice jaws, output end upwards.
2. At 2nd gear needle roller bearing, 2nd gear and synchromesh baulk rings onto mainshaft.
- (Rotate each baulk ring to ensure they locate onto each other).
3. Assemble the 1st and 2nd synchromesh selector hub onto mainshaft spline, (note 2nd speed side marking).
- Ensure that baulk ring has located correctly inside hub.
- (Rotate the ring slightly as the hub is lowered).
4. Install 1st gear synchromesh baulk rings, needle roller bearing, 1st gear and bush onto mainshaft ensuring baulk rings locate correctly inside selector hub.
5. Using LRT-99-002, bearing guide LRT-37-019, collets LRT-37-001 and adaptor LRT-37-002 press on mainshaft taper roller bearing taking care not to disturb the lay of the synchromesh baulk rings and gears.
6. Check the end float of the 1st and 2nd gear assembly using a feeler gauge between the gear and mainshaft bearing.
- Maximum clearance:
1st gear: 0.05 - 0.20mm (0.002 - 0.008 inch)
2nd gear: 0.04- 0.21mm (0.0016 - 0.0083 inch)
7. Invert mainshaft in vice and install 3rd gear needle roller bearing, third gear and synchromesh baulk rings.
8. Assemble 3rd/4th gear synchromesh selector hub (note 3rd speed side markings) onto mainshaft splines taking care to locate the baulk rings into recesses in the selector hub.
9. Install spacer
10. Using LRT-99-002 press on new pilot bearing.
- Check end float of 3rd gear assembly as in step 6.
- Maximum clearance: 0.11 - 0.21 mm.
REVERSE IDLE GEAR- REASSEMBLY
1. Examine components for wear and damage.
2. Assemble reverse idle gear needle roller bearing, idle gear, spacer and shaft and using suitable tool, press into center plate.
- Maximum clearance: 0.04 - 0.38mm (0.0016 - 0.015inch)
SELECTORS - INSPECTION
1. Examine selector rail and pins for wear and damage
2. Examine selector forks for wear and damage.
NOTE: The selector rail and fork is only supplied as a complete assembly.
3. Examine interlock spools for wear and damage.
Selector Quadrant - Type A Gearbox:
- Examine selector quadrant and check for wear.
Selector Yoke Type B And D Gearbox:
Selector Yoke, Type C Gearbox:
4. Remove snap ring and examine selector yoke assembly.
ASSEMBLING SELECTORS
1. Rest 1sV2nd fork and shah assembly on bench and locate pin in jaw of fork.
2. Install interlock spool and 3rd/4th fork and engage spool in jaw of fork.
3. Slide spool and fork towards 1st/2nd selector until slot in spool locates over pin keeping the spool engaged in 3rd/4th fork jaw.